Method of Manufacturing and Packing A Furniture Item&#39;s Components into A Shipping Box with Specified Geometry Requirements

ABSTRACT

A method of manufacturing and packing a furniture item&#39;s components into a shipping box with specified geometry requirements facilitates large furniture items such as sofas being packed into shipping boxes that are smaller than typical furniture dimensions by designing the furniture items accordingly. At least one shipping box is selected for a furniture item, wherein the at least one shipping box is sized to at least one specified geometric restriction. A plurality of assembly pieces are designed and sized for the furniture item in order for the assembly pieces to meet the at least one specified geometric restriction in a disassembled configuration. The assembly pieces are arranged into the disassembled configuration within the at least one shipping box, and the assembly pieces are confined within the at least one shipping box.

The current application claims a priority to the U.S. Provisional Patent application Ser. No. 62/647,473 filed on Mar. 23, 2018. The current application is filed on Mar. 25, 2019, whereas Mar. 23, 2019 and Mar. 24, 2019 were on a weekend.

FIELD OF THE INVENTION

The present invention relates generally to shipping. More specifically, the present invention is a method of producing and shipping furniture quickly and affordably.

BACKGROUND OF THE INVENTION

Furniture refers to movable objects intended to support various human activities such as seating (e.g., chairs, stools, and sofas), eating (tables), and sleeping (e.g., beds). Furniture is also used to hold objects at a convenient height for work (as horizontal surfaces above the ground, such as tables and desks), or to store things (e.g., cupboards and shelves). Furniture can be a product of design and is considered a form of decorative art. In addition to furniture's functional role, it can serve a symbolic or religious purpose. It can be made from many materials, including metal, plastic, and wood. Furniture can be made using a variety of woodworking joints which often reflect the local culture.

Since the advent of the Internet, the act of purchasing of goods has expanded significantly into buying products online from various retailers and other sellers, and buying furniture is no exception. However, since most furniture items are quite large compared to most other products purchasable online, shipping costs are typically quite high. This cost can be passed onto the consumer, at the detriment to consumer demand, or it can be absorbed by the company selling the furniture, at the detriment to the company's bottom line, or a balance between those two may be found.

Various shipping companies provide various levels of services, each with different pricing. Larger and heavier items are, as might be expected, more expensive to ship. However, certain services may be separated from each other by various cutoff thresholds related to dimensions, weight or other factors. Items exceeding these thresholds may be subject to markedly increased shipping costs versus complying with the thresholds. Items that are too large for typical ground shipping may be required to be shipped by freight, which has a high cost and long delivery times. Ground shipping, on the other hand, typically is lower cost and faster. Therefore, the cost of large furniture items such as sofas can in some cases be drastically reduced by designing them to fall under the relevant shipping thresholds in order to make use of the much less costly level of shipping service, such as ground shipping as opposed to freight shipping. Furthermore, ground shipping is more easily traceable by the consumer, as most shipping companies provide tracking numbers that can be accessed online in order to view the current shipping status.

It is therefore the objective of the present invention to introduce a method of manufacturing, packing and shipping large furniture items quickly and affordably.

Additional advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Additional advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the detailed description of the invention section. Further benefits and advantages of the embodiments of the invention will become apparent from consideration of the following detailed description given with reference to the accompanying drawings, which specify and show preferred embodiments of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a stepwise flow diagram describing the general method of the preferred embodiment of the present invention.

FIG. 2 is a stepwise flow diagram further describing the specified geometric restriction as a maximum threshold for a box length according to some embodiments.

FIG. 3 is a stepwise flow diagram further describing the specified geometric restriction as a maximum threshold for a box length plus a box girth according to some embodiments.

FIG. 4 is a stepwise flow diagram further describing the process for designing and sizing the plurality of assembly pieces according to some embodiments.

FIG. 5 is a stepwise flow diagram further describing the process for arranging the plurality of assembly pieces into the disassembled configuration.

FIG. 6 is a stepwise flow diagram describing steps for packing the plurality of assembly pieces into multiple shipping boxes.

FIG. 7 is an exemplary parts listing of a plurality of assembly pieces for a furniture item according to one embodiment.

FIG. 8 is an exemplary transformation of a sofa furniture item from a singular piece into a plurality of assembly pieces.

FIG. 9 is an exemplary comparison of assembly instructions of the furniture items of FIG. 8.

DETAIL DESCRIPTIONS OF THE INVENTION

All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention. The present invention is to be described in detail and is provided in a manner that establishes a thorough understanding of the present invention. There may be aspects of the present invention that may be practiced or utilized without the implementation of some features as they are described. It should be understood that some details have not been described in detail in order to not unnecessarily obscure focus of the invention. References herein to “the preferred embodiment”, “one embodiment”, “some embodiments”, or “alternative embodiments” should be considered to be illustrating aspects of the present invention that may potentially vary in some instances, and should not be considered to be limiting to the scope of the present invention as a whole.

The present invention is a method of designing, packing, and shipping furniture quickly and affordably. The present invention enables redesign and change of the construction and manufacturing process of furniture items so they can be packaged in one or more separate boxes that have specific geometric restrictions in order to comply with one or more shipping thresholds. In some embodiments, the shipping threshold is more specifically an “unauthorized oversized threshold”. The shipping threshold and/or requirements and/or category of shipping may vary among different shipping companies and/or services, such as, but not limited to, FedEx; more particularly, FedEx Ground.

Complying with said requirements facilitates several goals:

-   -   Saving a large amount of money per shipment, which converts         directly into gross profit.     -   Significantly lowered delivery time, as opposed to longer         shipping times through freight.     -   Traceability: the customer can track their order along its         shipping route.

With FedEx Ground® services, packages up to 150 lbs, up to 108″ in length and 165″ in length plus girth may be shipped. The present invention seeks to facilitate compliance with those restrictions, but should be understood to not be limited to them, and vary may in different embodiments according to different specific shipping restrictions from different shipping companies and different services within the companies. By splitting a sofa, for example, into multiple boxes of shorter length and girth, the shipment falls under the Unauthorized Oversized Threshold with FedEx Ground, leading to quicker shipping times, traceability, and lower costs.

Herein, various terms are used to refer to different dimensions and geometry of packages and components to be packaged: length is the longest side of the package or component; width is the next longest side, and height is the shortest side. Girth is defined as twice the width plus twice the height, or essentially the cross-sectional perimeter length of the package.

Referring to FIG. 1, in general, in the method of the present invention, at least one shipping box is selected for a furniture item (Step A), wherein each of the at least one shipping box is sized to at least one specified geometric restriction. Each of a plurality of assembly pieces for the furniture item is designed and sized in order for the plurality of assembly pieces to meet the at least one specified geometric restriction in a disassembled configuration (Step B). The disassembled configuration herein refers to a state where the plurality of assembly pieces are arranged together for shipping in a configuration that is capable of being placed within one or more shipping boxes. Moreover, the disassembled configuration arranged the plurality of assembly pieces within at least one rectangular prismatic boundary, as described in FIG. 5. The plurality of assembly pieces is arranged into the disassembled configuration within the at least one shipping box (Step C), and the plurality of assembly pieces is confined within a set of unextended boundaries of the at least one shipping box (Step D). To clarify, “unextended” is used herein to mean that the walls of the at least one shipping box should not need to flex substantially in order to arrange the plurality of assembly pieces within the shipping box or boxes.

In various embodiments, the at least one specified geometric restriction may comprise one or more restrictive parameters according to which the plurality of assembly pieces and the disassembled configuration thereof must be designed. In some embodiments, the at least one specified geometric restriction comprises a maximum threshold for a box length of the at least one shipping box. Referring to FIG. 2, in some embodiments, the maximum threshold for the box length is 108 inches, though in different embodiments, the maximum threshold for the box length may vary.

As seen in FIG. 3, in some embodiments, the at least one specified geometric restriction comprises a maximum threshold for a box length plus a box girth, wherein the box girth is twice a box width plus twice a box height of the at least one shipping box. In some embodiments, the maximum threshold for the box length plus box girth is less than or equal to 165 inches, though in different embodiments, the maximum threshold the box length plus box girth may vary. As previously mentioned, each box has length, width, and height dimensions, with the box width being less than or equal to the box length, and the box height being less than or equal to the box width. Alternatively stated, the box length is the longest dimension of the at least one shipping box, while the box width is the next longest dimension of the shipping box, and the box height is the shortest dimension of the shipping box. In some cases, the box length and box width may be equal to each other. In some cases, the box length, box width, and box height may all be equal to each other. Generally, however, the box length will be greater than the box width and the box height.

Each of the plurality of assembly pieces may be understood to be dimensioned with a piece length, a piece width, and a piece height, defined in a similar manner to the preceding discussion of dimensions. In some embodiments, for each of the plurality of assembly pieces, the piece length should be less than or equal to the box length, the piece width should be less than or equal to the box width, and the piece height should be less than or equal to the box height. Of course, any individual assembly piece should not exceed the dimensions of the shipping box. In some embodiments, it may be possible for the piece width of a particular piece to exceed the box width, or the piece height to exceed the box height, though the particular piece may be oriented to still fit within the dimensions of the shipping box; for example, by rotating the particular piece. The piece dimensions do not need to be oriented parallel to the box dimensions within the shipping box, and may be placed into any desired orientation that facilitates the plurality of assembly pieces being constrained within the dimensions of the shipping box.

In some embodiments, it may be desirable to design at least one of the plurality of assembly pieces to make maximal use of the dimensions of the shipping box. For example, a backrest piece of a sofa may be designed such that its piece length dimension is equal to, or nearly equal to the box length dimension with sufficient clearance for the piece to be capable of being placed into the shipping box. For example, if the box length of a shipping box is 68 inches, the piece length of the backrest piece may be 67 inches.

In some embodiments, in order to arrange the plurality of assembly pieces into the disassembled configuration, one or more pieces or portions thereof may be placed inside cavities or open space within the boundaries of another piece. To this end, as seen in FIG. 4, in some embodiments, at least one cavity for at least one specific piece may be sized to receive at least one portion of at least one other piece, wherein the at least one specific piece and the at least one other piece are from the plurality of assembly pieces. For example, a body piece may have a cavity or empty space within which a backrest piece is sized to fit, thus making maximal use of the space bounded by the dimensions of the body piece.

In some embodiments, it may be desirable to use two or more shipping boxes to ship the plurality of assembly pieces of a single furniture item. Thus, referring to FIG. 6, in some embodiments, the at least one shipping box may be provided as a plurality of shipping boxes, while the disassembled configuration may be provided as a plurality of physically-separated groupings. The plurality of assembly pieces are arranged into the plurality of physically-separated groupings, and each of the plurality of physically-separated groupings are confined within the set of unextended boundaries of a corresponding box from the plurality of shipping boxes.

Hereinafter follows an exemplary description according to one embodiment of the present invention. In the exemplary description, the furniture item is a sofa. The assembly pieces of the sofa are designed to be arranged into a disassembled configuration comprising a first physically-separated grouping and a second physically-separated grouping, with the first physically-separated grouping being confined within a first shipping box, and the second physically-separated grouping being confined within a second shipping box.

Referring to FIG. 7, in the exemplary description, the plurality of assembly items comprises, along with their respective length/width/height dimensions in inches:

a first body (67×29×13);

a first backrest (59×16×7);

four pillows (29×18);

two A cushions (29×22×6);

a second body (52×36×6);

a second backrest (28×16×8);

two armrests (29×10);

a B cushion (44×35×6);

eight A legs;

a B leg; and

a plurality of hardware pieces.

The first shipping box selected for the first physically-separated grouping has a box length of 68 inches, a box width of 30 inches, and a box height of 16 inches, resulting in a box length plus box girth of: 68+2*30+2*16=160, which is less than 165. The first physically-separated grouping contains, from the preceding component list:

the first body;

the first backrest;

two of the four pillows; and

the two A cushions.

The first body has an underframe cavity. The two A cushions are made to fit exactly into the underside cavity. The first body has a cavity within its dimensions which the first backrest is designed to fit into. After the first backrest is placed upon the first body, a space is still left into which the first two pillows can be placed, and due to the deformable nature of pillows they can be compressed to further facilitate their placement.

The second shipping box selected for the second physically-separated grouping has a box length of 54 inches, a box width of 37 inches, and a box height of 16 inches, resulting in a box length plus box girth of: 54+2*37+2*16=160, which is less than 165.

The second physically-separated grouping contains:

the second body;

the second backrest;

two of the four pillows;

the two armrests;

the B cushion;

the eight A legs;

the B leg; and

the plurality of hardware pieces.

The second body, having length and width dimensions of 52×36, is designed to maximally occupy the length and width dimensions of the second shipping box (52×37) with slight clearance to allow for packing. The second cushion is placed atop the second body. The second body is 52 inches in length while the second cushion is 44 inches in length, leaving a space of 8 inches, which is where the 8 inch height of the second backrest is placed. The remaining two of the four pillows and the second armrests are placed into a cavity under the second body, along with the eight A legs, the B leg, and the plurality of hardware pieces.

FIGS. 8-9 show a further exemplary transformation of a sofa from a singular piece into a plurality of assembly pieces and assembly instructions thereof.

Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed. 

What is claimed is:
 1. A method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method comprises the steps of: (A) selecting at least one shipping box for a furniture item, wherein each of the at least one shipping box is sized to at least one specified geometric restriction; (B) designing and sizing a plurality of assembly pieces for the furniture item in order for the plurality of assembly pieces to meet the at least one specified geometric restriction in a disassembled configuration; (C) arranging the plurality of assembly pieces into the disassembled configuration within the at least one shipping box; and (D) confining the plurality of assembly pieces within a set of unextended boundaries of the at least one shipping box.
 2. The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in claim 1, wherein the at least one specified geometric restriction comprises a maximum threshold for a box length.
 3. The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in claim 2, wherein the maximum threshold for the box length is 108 inches.
 4. The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in claim 1, wherein the at least one specified geometric restriction comprises a maximum threshold for a box length plus a box girth, and wherein the box girth is twice a box width plus twice a box height.
 5. The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in claim 4, wherein the maximum threshold for the box length plus box girth is less than or equal to 165 inches.
 6. The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in claim 4, wherein the box width is less than or equal to the box length, and wherein the box height is less than or equal to the box width.
 7. The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in claim 4, wherein each of the plurality of assembly pieces is dimensioned with a piece length, a piece width, and a piece height, and wherein the piece length is less than or equal to the box length, and wherein the piece width is less than or equal to the box width, and wherein the piece height is less than or equal to the box height.
 8. The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in claim 1, wherein the dissembled configuration arranges the plurality of assembly pieces within at least one rectangular prismatic boundary.
 9. The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in claim 1, wherein at least one cavity for at least one specific piece is sized to receive at least one portion of at least one other piece, and wherein the at least one specific piece and the at least one other piece are from the plurality of assembly pieces.
 10. The method of manufacturing and packing a furniture item's components into a shipping box with specified geometry requirements, the method as claimed in claim 1 comprises the steps of: providing the at least one shipping box as a plurality of shipping boxes; providing the disassembled configuration as a plurality of physically-separated groupings; arranging the plurality of assembly pieces into the plurality of physically-separated groupings; and confining each of the plurality of physically-separated groupings within the set of unextended boundaries of a corresponding box from the plurality of shipping boxes. 